Military style uniform hat



Dec. 9,1969 w. H. WAGNER 3,482,266

MILITARY STYLE UNIFQRM HAT Filed Dec. 1, 1967 2 Sheets-Sheet 1 a2 I) W l f-fl 2 If .I V 2a H a I F I l Z6 BY I I w mm ATTORNEY5 Dec. 9, 1969 w. H. WAGNER MILITARY STYLE UNIFORM HAT 2 Sheets-Sheet 2 Filed Dec. 1. 1967 INVENTOR wvse ATTORNEYS United States Patent 3,482,266 MILITARY STYLE UNIFORM HAT William H. Wagner, Fort Lauderdale, Fla., assignor to Bayly, Inc., Hollywood, Fla., a corporation of Florida Filed Dec. 1, 1967, Ser. No. 687,232 Int. Cl. A42c /00 US. Cl. 2-180 5 Claims ABSTRACT OF THE DISCLOSURE A hat skeleton for a military style uniform hat comprises a rigid, frame unit formed from plastic material by injection molding, a resilient plastic head-encircling band and a circular stiffening ring or grommet. The frame unit includes a generally arcuate section having a specially curved concave surface which receives a circumferential portion of the band and deflects the latter into a generally oval shape. A visor section and a stayer section are integrally molded with the band-supporting section. The grommet is supported in an inclined position relative to the band by attachment to a rearwardly inclined lip at the upper edge of the stayer section.

This invention relates to military style uniform hats or caps and in particular to an improved frame construction for hats of this kind.

Military style uniform hats generally include as their essential elements a band which encircles the head of the wearer, a visor or peak projecting downwardly and forwardly from the band, a stayer which extends upwardly from the front of the band for providing support for the typical upstanding front portion of the hat, and a grommet or stiffening ring which provides support and shape for the cover or top portion of the hat. These essential elements are fastened together in a variety of ways to form a skeleton or main frame which determines the basic overall shape of the hat. In many conventional hat constructions the elements, particularly the band, visor and stayer, are separately constructed pieces, often made up of lesser parts, which are then sewn, riveted or otherwise interconnected by a series of assembly steps. In order to avoid some of these operations it has been suggested in the past to mold the entire band, visor and stayer in one piece. While the latter method simplifies the assembly of the hat it is not readily adapted for making hats of different head sizes inasmuch as different units must be molded for each head size, or an additional band structure of adjustable construction must be supplied. Further, the band portion should be resilient or flexible, and the stayer and visor portions should be rigid and fixed with respect to each other, and this combination of features is difficult to attain in a single molded unit.

The present invention provides a rigid hat frame unit which is formed from plastic material by injection molding in a special shape which effects several structural and functional advantages over prior constructions. The frame unit includes an arcuate band-supporting section contoured generally to the forehead and temples of the wearer, a visor or peak portion integrally molded with the band section, and a stayer section also molded integrally with the band section. In using the frame unit in assembling a hat a normally circular resilient ban-d, conveniently constructed of plastic, is fitted against the concave surface of the band-supporting section of the frame unit and is deflected by the special curvature into a gen erally oval shape so as to better fit the wearer. Different hat sizes are readily obtained by employing bands of different diameters, each of these being made most simply by cutting a semi-rigid, flexible plastic strip to an appropriate length and fastening the free ends together.

A further feature of the frame unit is the provision of a rearwardly inclined grommet-supporting flange or lip along the upper edge of the stayer portion. The grommet is a resilient ring preferably formed of metal strip or flat wire and is fastened with its wide surface flush against the stayer flange so that the grommet is effectively supported in the downwardly and rearwardly inclined position which is typical of military style uniform hats.

A further feature of the frame unit is the overall support and shape which it lends to the hat due to the rigidity of the unit and the fixed relationship which it maintains between the stayer section, band section and visor section. Since no relative movement can occur between these parts, the grommet and band do not become displaced by prolonged use, and hence the overall shape of the hat is maintained.

The invention will be further understood from the following detailed description of an illustrative embodiment taken with the drawings in which:

FIGURE 1 is a side elevational view of a hat frame embodying a frame unit constructed according to the principles of the present invention;

FIGURE 2 is a top view, on an enlarged scale, of the frame unit of FIGURE 1;

FIGURE 3 is a sectional view taken on the line 3-3 of FIGURE 2;

FIGURE 4 is a sectional view taken on the line 4-4 of FIGURE 2;

FIGURE 5 is a front view of the frame unit;

FIGURE 6 is a bottom view of the frame unit; and

FIGURES 7 and 8 are schematic top views illustrating one of the steps by which the hat frame of FIGURE 1 is assembled. I

FIGURE 1 illustrates in simplified form a hat skeleton or main frame which includes a rigid molded frame unit 10 embodying the principles of the present invention. In the interest of clarity only the essential elements of the skeleton are illustrated, although a conventional cloth covering 12 and emblem 14 are shown in broken lines in order to establish the relationship between the skeleton and a completed hat. As shown, the essential elements of the skeleton include, in addition to the molded frame unit 10, a resilient head-encompassing band 16 and a grommet 18 or stiffening ring. The band 16, which is a separate piece from the molded frame unit 10 is ring-shaped and preferably is formed of semirigid yet flexible plastic strip material. The grommet 18, also a separate piece, is a resilient ring-shaped member preferably formed of metal strip or flat wire. As illustrated somewhat schematically in FIGURES 7 and 8 a circumferential portion of the band 16 is fitted against and fastened to a special concave surface on the frame unit 10 so as to be deflected and restrained in an oval shape, this feature being described more in detail hereinafter.

The frame unit 10, which is the principal element of the present invention, is illustrated in side elevation in FIGURE 1 and other details are shown in FIGURES 2 through 6. It is an integral structure formed by injection molding of suitable plastic material, such as ABS (acrylonitrile-butadiene-styrene terpolymers and blends), in a thickness sufficient to provide rigidity and strength consistent with light weight. The central part of the frame unit is an arcuate band-supporting section having two free end portions 22 and 24. The concave curvatures of the end portions 22 and 24 and of the intermediate portion 26 between the end portions are of special design and together are generally complementary to the temples and forehead of the wearer. In a completed hat the end portions 22 and 24 terminate slightly forward of the ears of the wearer.

The lower portion of the frame unit 10 is a visor or peak section 28 integrally molded with the band-supporting section 20 and coextensive therewith to provide rigidity. The visor section 28 projects downwardly and forwardly from the band-supporting section 20 at an appropriate angle and may be of any desired shape in plan view. As shown, the forward edge of the visor section is continuously rounded and terminates in a slightly thickened head or lip 30 which enhances the appearance and strength of the visor section 28.

The upper portion of the frame unit is a stayer section 32 integrally molded with the band-supporting section 20 along the central portion of the upper edge of the latter and extending upwardly and forwardly. As best shown in FIGURES 2 and 5, the stayer section 32 is an arcuate plate-like structure which is trapezoidal when viewed from the front. Conveniently an aperture 34 will be provided near the center to receive the stud of the emblem 14, as illustrated in FIGURE 1. The upper edge of the stayer section 32 terminates in a rearwardly and upwardly directed flange 36 which increases the rigidity of the structure and provides support for the grommet 18. The

grommet 18 is preferably formed of flat strip material rather than round wire, and the width of flange 36 is preferably at least as wide as the grommet 18. By this arrangement the grommet 18, when fastened mechanically to the flange 36, is held securely against movement relative to the frame unit 10. In addition, the angular position of the flange 36 assures that the grommet 18 will incline rearwardly and downwardly so as to effect the desired shape to the top of the hat, as seen in FIGURE 1.

The grommet 18 is attached to the stayer flange 36 in any suitable manner. In the illustrated embodiment the upper edge of the flange 36 is provided with a groove 38 which will receive the grommet 18 and retain the same by a friction fit. Alternatively, the grommet 18 may be secured to the flange 36 with rivets or other fastening means.

Referring again to the curvature of the band-supporting section 24, it will be seen from FIGURES 7 and 8 that the concave surface of this part of the molded frame unit 10 deflects the circular band 16 into a generally oval shape when the band 16 is pressed into engagement with the section 24, thereby shaping the band 16 to the natural contours of the wearers head. The band 16, therefore, need not be pre-shaped and may be made simply by joining the two ends of a strip of flexible, semirigid plastic to form a circular ring. Different sizes of bands may be made, of course, by selecting different lengths of strip material, that is, by making rings of different diameters. In order for the frame unit 10 to deflect a circular band 16 the diameter of the latter must be greater than the distance between the two ends 22 and 24 of the bandsupporting section 20. A distance of about 6% inches has been found suitable for imparting and retaining an oval shape for most. head sizes. In addition, the concave curvature of the end portions 22 and 24 should be of greater radius of curvature than the curvature of the center portion 26, because this assures that the ends 22 and 24 will contact the band 16 first and deflect it before it seats against the center portion 26. Any suitable attachment means for securing the band 16 to the frame unit may be employed, such as rivets or screws (not shown).

Specifically, and referring to FIGURE 2, the inner curvature of the band-retaining section 20 is made up of three circular arcs merged together smoothly to form a concave surface which is generally oval. The central portion 26 of the surface is a circular are measured about a center A which lies on the center line of the frame unit as viewed in plan. A typical radius for this are is 2% inches. The end portion 22 of the surface is a circular arc of greater radius than the center are and is measured from a center B which is positioned re-arwardly of the center A and offset from the center line in a direction away from the end portion 22. The end portion 24 is a circular arc of the same radius as the portion 22 and is measured from the center C on the other side of the center line from the center B. A typical radius for these two arcs is 4 inches.

The assembly of a complete hat using the frame unit 10, band 16 and grommet 18 may be carried out in a variety of ways depending on various ornamental considerations and the selection of the covering and lining materials. In each case, however, the integral frame unit 10 stabilizes the shape of the hat due to its rigid structure. That is, the forward inclination of the stayer section 32 and the upright position of the band section 20 are maintained, because no relative movement between portions of the frame unit 10 can take place. The stabilizing influence is transmitted to the band 16 and to the grommet 18 by virtue of their connection to the frame unit 10. Further, the special shape of the band-supporting section 20 assures that any of a variety of band sizes will assume an oval shape, and the inclined stayer flange 36 assures that the grommet 18 will assume an inclined position relative to the band 16.

While a preferred embodiment of the present invention has been described, further modifications may be made without departing from the scope of the invention.

What is claimed is:

1. A substantially rigid, integrally molded plastic frame unit for use in constructing a military style uniform hat, said frame unit having: a band-supporting portion of continuous generally arcuate shape adapted to conform to the forehead and temples of the wearer, and having an upper edge, two free ends, a convex outer surface and a concave inner surface; a visor portion integral with said band-supporting portion and extending downwardly and forwardly therefrom; and a stayer portion integral with said band-supporting portion along the central part of said upper edge and extending upwardly from said central part of said upper edge of said band-supporting portion.

2. A hat frame as in claim 1 wherein said stayer portion is generally arcuate when viewed from above and terminates at its upper edge in an integral flange which is inclined upwardly and slightly rearwardly from said stayer portion so as to be capable of accommodating a grommet or the like.

3. A hat frame as in claim 1 wherein said band-supporting portion curves in an arc of greater radius near each free end than at the central portion whereby a resilient circular band which has a diameter larger than the straight-line distance between the two free ends of said band-engaging portion will be deflected into a generally elliptical shape when pressed into engagement with the concave surface of said band-supporting portion.

4. A hat frame as in claim 1 wherein said band-supporting portion curves in a first circular arc in its central region, the radius of curvature being measured from a first center located midway between said free ends and then curves at said free ends in equal circular arcs of greater radius measured from centers disposed rearwardly of and laterally offset from said first center on opposite sides of said first center.

5. A hat frame comprising the integrally molded frame of claim 1 in combination with a normally generally circular, resilient band of a size to fit the wearers head, a circumferential portion of said band being fitted to the 5 6 concave surface of said band-supporting portion and FOREIGN PATENTS deflected by the latter into a generally elliptical shape. 233,290 5/1925 England.

Refe'ences Cited MERVIN STEIN, Primary Examiner UNITED STATES PATENTS 2,617,111 11/1952 Lev 2195 2,848,720 8/1958 Krieger 2-199 5 GEORGE H. KRIZMANICH, Assistant Examiner 

